Emerging Technology: Report on Development of an Enhanced Plastisol Coating System for Atmospheric, Transitional, and Soil and/or Water Immersed Applications on Steel Substrates

摘要

For the past seven years we have been testing a plasticized polyvinyl chloride formulation with the goal of developing and patenting an Enhanced Plastisol Coating (EPC) formulation and application System (EPCS) for the purpose of corrosion mitigation over a wide range of industries. Plasticized polyvinyl chloride has been shown over decades of use to be durable and effective as an anti-corrosion coating. Our research comparing EPC to widely used coatings, along with Four-Tier Testing by EPRI(~1) and other independent research facilities, has shown that EPC performs well in atmospheric, transitional, and in water and/or soil immersed applications. In December 2012, the Alabama Department of Transportation(~2) completed a Coastal Exposure Test of the EPC in Orange Beach, Alabama. An EPC-coated, galvanized steel post was placed in the bay at Perdido Pass for 13 months alongside a galvanized post. Results indicated that the EPC prevented rust and degradation at the splash zone, and was impermeable to marine life below and UV above. In stark contrast, the integrity of the galvanized steel post was severely compromised by red rust and pitting. Because the EPC requires heat to cure, we have developed an EPCS to apply it. We found that EPC reacts with a specific type of infrared energy, within a certain wavelength range, to achieve a cured state. The EPCS utilizes an array of infrared generators and moves over the substrate surface by way of a variety of drive systems. The EPCS has been demonstrated and proven to work on large, smooth substrates, applying a ≥ 62 mil EPC layer. In conclusion, we believe the development of the EPCS provides multiple industries with a single, effective coating for atmospheric, transitional, and immersion applications.